Optical laminate having hard coat layer composition with specified quantities of monofunctional monomer and varied (meth)acryloyl group containing compounds

ABSTRACT

There is provided an optical laminate excellent which secures adhesiveness between the (meth)acrylic resin film (base material film) and a hard coat layer, and can prevent a reduction in scratch resistance. An optical laminate according to an embodiment of the present invention includes: a base material layer formed of a (meth)acrylic resin film; a hard coat layer formed by applying, to the (meth)acrylic resin film, a composition for forming a hard coat layer containing a curable compound and inorganic nanoparticles; and a penetration layer having a thickness of 1.2 μm or more, the penetration layer being formed between the base material layer and the hard coat layer by penetration of the composition for forming a hard coat layer into the (meth)acrylic resin film, wherein a content of the inorganic nanoparticles is 1.5 wt % to 50 wt % with respect to a total of the curable compound and the inorganic nanoparticles.

TECHNICAL FIELD

The present invention relates to an optical laminate.

BACKGROUND ART

When the surface of an image display apparatus such as a liquid crystal display (LCD), a cathode-ray tube display apparatus (CRT), a plasma display (PDP), or an electroluminescence display (ELD) is flawed by external contact, the visibility of a display image may reduce. Accordingly, an optical laminate including abase material film and a hard coat layer has been used for the purpose of protecting the surface of the image display apparatus. Triacetylcellulose (TAC) has been representatively used in the base material film of the optical laminate (Patent Literature 1). However, the base material film formed of TAC has a high moisture permeability. Accordingly, when the optical laminate including such base material film is used in the LCD, the following problem arises. Under high temperature and high humidity, moisture permeates the optical laminate to deteriorate the optical characteristics of a polarizer. In recent years, the LCD has been frequently used in devices to be used outdoors such as a car navigation system and a personal digital assistant in addition to indoor use, and hence a high-reliability LCD that does not cause the problem even under severe conditions such as high temperature and high humidity has been required.

The following optical laminate has been proposed for solving the problem (Patent Literature 2). The optical laminate has a hard coat layer formed by applying a composition for forming a hard coat layer onto a low-moisture permeability acrylic base material film and drying the composition. Although the optical laminate described in Patent Literature 2 has some degree of adhesiveness between the base material film and the hard coat layer, the adhesiveness is not sufficient yet and adhesiveness comparable to that of the base material film formed of TAC has not been obtained.

PRIOR ART DOCUMENTS Patent Documents

[PTL 1] JP 2008-165205 A

[PTL 2] JP 2009-185282 A

SUMMARY OF INVENTION Problem to be Solved by the Invention

With regard to the adhesiveness between the acrylic base material film and the hard coat layer, the inventors of the present invention have investigated their close adhesion through an anchor effect. As a result, the inventors have found the following new problem. When an attempt is made to improve the adhesiveness (representatively, to increase the drying temperature of the composition for forming a hard coat layer), a base material film component is eluted into the hard coat layer to reduce its scratch resistance. The present invention has been made to solve the problem and an object of the present invention is to provide the following optical laminate. Even when a (meth)acrylic resin film (base material film) containing a low-moisture permeability (meth)acrylic resin is used, the optical laminate secures adhesiveness between the (meth)acrylic resin film (base material film) and a hard coat layer, and can prevent a reduction in scratch resistance.

Means for Solving the Problems

An optical laminate according to an embodiment of the present invention includes: a base material layer formed of a (meth)acrylic resin film; a hard coat layer formed by applying, to the (meth)acrylic resin film, a composition for forming a hard coat layer containing a curable compound and inorganic nanoparticles; and a penetration layer having a thickness of 1.2 μm or more, the penetration layer being formed between the base material layer and the hard coat layer by penetration of the composition for forming a hard coat layer into the (meth)acrylic resin film, wherein a content of the inorganic nanoparticles is 1.5 wt % to 50 wt % with respect to a total of the curable compound and the inorganic nanoparticles.

In an embodiment of the present invention, at least part of a surface of each of the inorganic nanoparticles is covered with an organic compound.

In an embodiment of the present invention, the organic compound includes an organic compound having a polymerizable unsaturated group.

In an embodiment of the present invention, the content of the inorganic nanoparticles is 1.5 wt % to 30 wt % with respect to the total of the curable compound and the inorganic nanoparticles.

In an embodiment of the present invention, the composition for forming a hard coat layer contains a curable compound having 5 or more (meth)acryloyl groups, and a content of the curable compound having 5 or more (meth)acryloyl groups is 15 wt % to 100 wt % with respect to all curable compounds in the composition for forming a hard coat layer.

In an embodiment of the present invention, the composition for forming a hard coat layer contains a curable compound having 2 to 4 (meth)acryloyl groups, and a content of the curable compound having 2 to 4 (meth)acryloyl groups is 85 wt % or less with respect to all curable compounds in the composition for forming a hard coat layer.

In an embodiment of the present invention, the composition for forming a hard coat layer further contains a monofunctional monomer, and a content of the monofunctional monomer is 40 wt % or less with respect to all curable compounds in the composition for forming a hard coat layer.

In an embodiment of the present invention, the monofunctional monomer has a weight-average molecular weight of 500 or less.

In an embodiment of the present invention, the monofunctional monomer has a hydroxyl group.

In an embodiment of the present invention, the monofunctional monomer includes a hydroxyalkyl (meth)acrylate and/or an N-(2-hydroxyalkyl) (meth)acrylamide.

In an embodiment of the present invention, the (meth)acrylic resin film has a transmittance for light having a wavelength of 380 nm of 15% or less.

In an embodiment of the present invention, a (meth)acrylic resin forming the (meth)acrylic resin film has a structural unit expressing positive birefringence and a structural unit expressing negative birefringence.

In an embodiment of the present invention, a (meth)acrylic resin forming the (meth)acrylic resin film has a weight-average molecular weight of 10,000 to 500,000.

In an embodiment of the present invention, in the hard coat layer and the penetration layer, a concentration of a (meth)acrylic resin forming the (meth)acrylic resin film continuously reduces from a side of the penetration layer close to the base material layer to a side of the hard coat layer opposite to the base material layer.

In an embodiment of the present invention, a surface of the hard coat layer opposite to the penetration layer has an uneven structure.

In an embodiment of the present invention, the optical laminate further includes an antireflection layer on a side of the hard coat layer opposite to the penetration layer.

According to another aspect of the present invention, a polarizing film is provided. The polarizing film includes the optical laminate.

According to another aspect of the present invention, an image display apparatus is provided. The image display apparatus includes the optical laminate.

Advantageous Effects of Invention

According to the present invention, the following optical laminate can be obtained by forming a hard coat layer with a composition for forming a hard coat layer containing inorganic nanoparticles at a specific content. Even when a low-moisture permeability (meth)acrylic resin film (base material film) is used, the optical laminate is excellent in both adhesiveness between the (meth)acrylic resin film (base material film) and the hard coat layer, and scratch resistance of the hard coat layer.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1(a) is a schematic sectional view of an optical laminate according to a preferred embodiment of the present invention and FIG. 1(b) is a schematic sectional view of a conventional optical laminate having a general hard coat layer.

DESCRIPTION OF EMBODIMENTS

Hereinafter, preferred embodiments of the present invention are described but the present invention is not limited to these embodiments.

A. Entire Construction of Optical Laminate

FIG. 1(a) is a schematic sectional view of an optical laminate according to a preferred embodiment of the present invention and FIG. 1(b) is a schematic sectional view of a conventional optical laminate having a general hard coat layer. An optical laminate 100 illustrated in FIG. 1(a) includes a base material layer 10 formed of a (meth)acrylic resin film, a penetration layer 20, and a hard coat layer 30 in the stated order. The hard coat layer 30 is formed by applying a composition for forming a hard coat layer containing a curable compound to the (meth)acrylic resin film. The penetration layer 20 is formed by the penetration of the composition for forming a hard coat layer into the (meth)acrylic resin film. The base material layer 10 is a portion in the (meth)acrylic resin film where the composition for forming a hard coat layer has not reached (penetrated) at the time of such penetration of the composition for forming a hard coat layer into the (meth)acrylic resin film. On the other hand, no penetration layer is formed in an optical laminate 200 illustrated in FIG. 1(b). A boundary A illustrated in each of FIGS. 1(a) and 1(b) is a boundary specified by the surface of the (meth)acrylic resin film to which the composition for forming a hard coat layer is applied. Therefore, the boundary A is a boundary between the penetration layer 20 and the hard coat layer 30 in the optical laminate 100, and is a boundary between a base material layer 10′ (i.e., the (meth)acrylic resin film) and a hard coat layer 30′ in the optical laminate 200 in which no penetration layer is formed. It should be noted that the term “(meth)acryl” as used herein means acryl and/or methacryl.

As described above, the penetration layer 20 is formed by the penetration of the composition for forming a hard coat layer into the (meth)acrylic resin film in the optical laminate 100. That is, the penetration layer 20 is a portion in the (meth)acrylic resin film where a hard coat layer component is present. The thickness of the penetration layer 20 is 1.2 μm or more. It should be noted that the thickness of the penetration layer 20 is the thickness of the portion in the (meth)acrylic resin film where the hard coat layer component is present, and the thickness is specifically a distance between a boundary B between the portion in the meth (acrylic) resin film where the hard coat layer component is present (penetration layer) and the portion in the film where the component is not present (base material layer), and the boundary A.

The composition for forming a hard coat layer to be used in the present invention further contains inorganic nanoparticles. The inorganic nanoparticles 1 are present in the hard coat layer 30 formed of the composition for forming a hard coat layer. When the hard coat layer 30 containing the inorganic nanoparticles 1 is formed with the composition for forming a hard coat layer containing the inorganic nanoparticles, a component in the (meth)acrylic resin film that has been eluted into the composition for forming a hard coat layer (representatively a resin component in the (meth)acrylic resin film) is prevented from diffusing to the air interface of the hard coat layer at the time of the formation of the hard coat layer, and hence an optical laminate excellent in scratch resistance can be obtained.

In the optical laminate of the present invention, any appropriate other layer (not shown) may be placed outside the hard coat layer 30 as required. The other layer is representatively placed through a pressure-sensitive adhesive layer (not shown).

A (meth)acrylic resin forming the (meth)acrylic resin film may be present in the hard coat layer as a result of the elution of the (meth)acrylic resin into the composition for forming a hard coat layer. According to the present invention, even when the (meth)acrylic resin is present in the hard coat layer, an optical laminate excellent in scratch resistance can be obtained. It is preferred that in the hard coat layer 30 and the penetration layer 20, the concentration of the (meth)acrylic resin forming the (meth)acrylic resin film continuously reduce from the side of the penetration layer 20 close to the base material layer 10 to the side of the hard coat layer 30 opposite to the base material layer 10 (i.e., the air-side interface of the hard coat layer 30). This is because of the following reason. When the concentration of the (meth)acrylic resin continuously changes, i.e., no interface resulting from a change in concentration of the (meth)acrylic resin is formed, interface reflection can be suppressed and hence an optical laminate showing small interference unevenness can be obtained.

The amplitude of the reflection spectrum of the hard coat layer of the optical laminate of the present invention in the wavelength region of 500 nm to 600 nm is preferably 1.0% or less, more preferably 0.5% or less, still more preferably 0.3% or less, particularly preferably 0.1% or less. According to the present invention, an optical laminate having a small amplitude of a reflection spectrum, i.e., small interference unevenness can be obtained.

The optical laminate of the present invention has the penetration layer having a predetermined thickness. Accordingly, even when materials largely different from each other in refractive index are selected as formation materials for the (meth)acrylic resin film and the hard coat layer, the occurrence of interference unevenness can be prevented. In the optical laminate of the present invention, the absolute value of a difference between the refractive index of the base material layer and the refractive index of the hard coat layer can be set to, for example, 0.01 to 0.15. Of course, the absolute value of the difference in refractive index can be set to less than 0.01.

The optical laminate of the present invention is applied to, for example, a polarizing film (sometimes referred to as “polarizing plate”). Specifically, in the polarizing film, the optical laminate of the present invention is provided on one surface, or each of both surfaces, of a polarizer, and can be suitably used as a protective material for the polarizer.

B. Base Material Layer

The base material layer is formed of the (meth)acrylic resin film. More specifically, as described above, the base material layer is the portion in the (meth)acrylic resin film where the composition for forming a hard coat layer has not reached (penetrated) upon application of the composition for forming a hard coat layer to the (meth)acrylic resin film.

The (meth)acrylic resin film contains the (meth)acrylic resin. The (meth)acrylic resin film is obtained by, for example, subjecting a forming material containing a resin component containing the (meth)acrylic resin as a main component to extrusion molding.

The moisture permeability of the (meth)acrylic resin film is preferably 200 g/m²·24 hr or less, more preferably 80 g/m²·24 hr or less. According to the present invention, even when the (meth)acrylic resin film having such high moisture permeability is used, an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained. It should be noted that the moisture permeability can be measured by, for example, a method in conformity with JIS 20208 under the test conditions of 40° C. and a relative humidity of 92%.

The (meth)acrylic resin film has a transmittance for light having a wavelength of 380 nm of preferably 15% or less, more preferably 12% or less, still more preferably 9% or less. As long as the transmittance for light having a wavelength of 380 nm falls within such range, an excellent UV absorbing ability is expressed and hence the UV deterioration of the optical laminate due to ambient light or the like can be prevented.

The (meth)acrylic resin film has an in-plane retardation Re of preferably 10 nm or less, more preferably 7 nm or less, still more preferably 5 nm or less, particularly preferably 3 nm or less, most preferably 1 nm or less. The (meth)acrylic resin film has a thickness direction retardation Rth of preferably 15 nm or less, more preferably 10 nm or less, still more preferably 5 nm or less, particularly preferably 3 nm or less, most preferably 1 nm or less. As long as the in-plane retardation and the thickness direction retardation fall within such ranges, adverse effects on the display characteristics of an image display apparatus resulting from the retardations can be significantly suppressed. More specifically, interference unevenness and the distortion of a 3D image when the film is used in a liquid crystal display apparatus for 3D display can be significantly suppressed. The (meth)acrylic resin film whose in-plane retardation and thickness direction retardation fall within such ranges can be obtained by using, for example, a (meth)acrylic resin having a glutarimide structure to be described later. It should be noted that the in-plane retardation Re and the thickness direction retardation Rth are determined from the following respective equations. Re=(nx−ny)×d Rth=(nx−nz)×d Here, nx represents the refractive index of the (meth)acrylic resin film in its slow axis direction, ny represents the refractive index of the (meth)acrylic resin film in its fast axis direction, nz represents the refractive index of the (meth)acrylic resin film in its thickness direction, and d (nm) represents the thickness of the (meth)acrylic resin film. The term “slow axis” refers to the direction in which a refractive index in a film surface becomes maximum and the term “fast axis” refers to a direction vertical to the slow axis in the surface. The Re and the Rth are representatively measured with light having a wavelength of 590 nm.

Any appropriate (meth)acrylic resin may be adopted as the (meth)acrylic resin. Examples thereof include poly(meth)acrylates such as polymethyl methacrylate, a methyl methacrylate-(meth)acrylic acid copolymer, a methyl methacrylate-(meth)acrylate copolymer, a methyl methacrylate-acrylate-(meth)acrylic acid copolymer, a methyl (meth)acrylate-styrene copolymer (such as an MS resin), and polymers each having an alicyclic hydrocarbon group (such as a methyl methacrylate-cyclohexyl methacrylate copolymer and a methyl methacrylate-norbornyl (meth)acrylate copolymer). Of those, a poly C₁₋₆ alkyl (meth)acrylate such as polymethyl (meth)acrylate is preferably given. A methyl methacrylate-based resin including methyl methacrylate as a main component (50 to 100% by weight, preferably 70 to 100% by weight) is more preferably given.

The weight-average molecular weight of the (meth)acrylic resin is preferably 10,000 to 500,000, more preferably 30,000 to 500,000. According to the present invention, even when a (meth)acrylic resin having a small weight-average molecular weight is used, i.e., a (meth)acrylic resin that is eluted into the hard coat layer in a relatively easy manner is used, an optical laminate excellent in scratch resistance can be obtained. When a (meth)acrylic resin having a small weight-average molecular weight is used, a penetration layer having a sufficient thickness is formed in the (meth)acrylic resin film, and hence an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained.

The glass transition temperature of the (meth)acrylic resin is preferably 110° C. or more, more preferably 120° C. or more. As long as the glass transition temperature falls within such range, a (meth)acrylic resin film excellent in durability and heat resistance can be obtained. An upper limit for the glass transition temperature, which is not particularly limited, is preferably 170° C. or less from the viewpoint of, for example, formability.

The (meth)acrylic resin preferably has a structural unit expressing positive birefringence and a structural unit expressing negative birefringence. As long as the resin has those structural units, the retardations of the (meth)acrylic resin film can be controlled by adjusting an abundance ratio between the units, and hence a (meth)acrylic resin film having low retardations can be obtained. Examples of the structural unit expressing positive birefringence include a structural unit constituting a lactone ring, polycarbonate, polyvinyl alcohol, cellulose acetate, polyester, polyallylate, polyimide, polyolefin, or the like, and a structural unit represented by the general formula (1) to be described later. Examples of the structural unit expressing negative birefringence include a structural unit derived from a styrene-based monomer, maleimide-based monomer, or the like, a structural unit of a polymethyl methacrylate, and a structural unit represented by the general formula (3) to be described later. The term “structural unit expressing positive birefringence” as used herein means a structural unit in the case where a resin having only the structural unit shows a positive birefringent characteristic (i.e., the case where a slow axis is expressed in a stretching direction of the resin). In addition, the term “structural unit expressing negative birefringence” means a structural unit in the case where a resin having only the structural unit shows a negative birefringent characteristic (i.e., the case where a slow axis is expressed in a direction vertical to a stretching direction of the resin).

A (meth)acrylic resin having a lactone ring structure or a glutarimide structure is preferably used as the (meth)acrylic resin. The (meth)acrylic resin having a lactone ring structure or a glutarimide structure is excellent in heat resistance. The (meth)acrylic resin having a glutarimide structure is more preferred. The use of the (meth)acrylic resin having a glutarimide structure can provide a (meth)acrylic resin film having low moisture permeability, small retardations, and a small UV transmittance as described above. The (meth)acrylic resin having a glutarimide structure (hereinafter sometimes referred to as “glutarimide resin”) is described in, for example, Japanese Patent Application Laid-open No. 2006-309033, Japanese Patent Application Laid-open No. 2006-317560, Japanese Patent Application Laid-open No. 2006-328329, Japanese Patent Application Laid-open No. 2006-328334, Japanese Patent Application Laid-open No. 2006-337491, Japanese Patent Application Laid-open No. 2006-337492, Japanese Patent Application Laid-open No. 2006-337493, Japanese Patent Application Laid-open No. 2006-337569, Japanese Patent Application Laid-open No. 2007-009182, or Japanese Patent Application Laid-open No. 2009-161744. Those descriptions are incorporated herein by reference.

The glutarimide resin preferably contains a structural unit represented by the following general formula (1) (hereinafter sometimes referred to as “glutarimide unit”) and a structural unit represented by the following general formula (2) (hereinafter sometimes referred to as “(meth)acrylate unit”).

In the formula (1), R¹ and R² each independently represent hydrogen or an alkyl group having 1 to 8 carbon atoms, and R³ represents hydrogen, an alkyl group having 1 to 18 carbon atoms, a cycloalkyl group having 3 to 12 carbon atoms, or a substituent containing an aromatic ring having 5 to 15 carbon atoms. In the formula (2), R⁴ and R⁵ each independently represent hydrogen or an alkyl group having 1 to 8 carbon atoms, and R⁶ represents hydrogen, an alkyl group having 1 to 18 carbon atoms, a cycloalkyl group having 3 to 12 carbon atoms, or a substituent containing an aromatic ring having 5 to 15 carbon atoms.

The glutarimide resin may further contain a structural unit represented by the following general formula (3) (hereinafter sometimes referred to as “aromatic vinyl unit”) as required.

In the formula (3), R⁷ represents hydrogen or an alkyl group having 1 to 8 carbon atoms and R⁸ represents an aryl group having 6 to 10 carbon atoms.

It is preferred that in the general formula (1), R¹ and R² each independently represent hydrogen or a methyl group, and R³ represent hydrogen, a methyl group, a butyl group, or a cyclohexyl group. It is more preferred that R¹ represent a methyl group, R² represent hydrogen, and R³ represent a methyl group.

The glutarimide resin may contain only one kind of glutarimide unit, or may contain a plurality of kinds of glutarimide units different from each other in R¹, R², or R³ in the general formula (1).

The glutarimide unit can be formed by imidizing the (meth)acrylate unit represented by the general formula (2). In addition, the glutarimide unit can be formed by imidizing: an acid anhydride such as maleic anhydride, or a half ester of such acid anhydride and a linear or branched alcohol having 1 to 20 carbon atoms; an α,β-ethylenically unsaturated carboxylic acid such as acrylic acid, methacrylic acid, maleic acid, maleic anhydride, itaconic acid, itaconic anhydride, crotonic acid, fumaric acid, or citraconic acid; or the like.

It is preferred that in the general formula (2), R⁴ and R⁵ each independently represent hydrogen or a methyl group, and R⁶ represent hydrogen or a methyl group. It is more preferred that R⁴ represent hydrogen, R⁵ represent a methyl group, and R⁶ represent a methyl group.

The glutarimide resin may contain only one kind of (meth)acrylate unit, or may contain a plurality of kinds of (meth)acrylate units different from each other in R⁴, R⁵, or R⁶ in the general formula (2).

The glutarimide resin contains, as the aromatic vinyl unit represented by the general formula (3), preferably styrene, α-methylstyrene, or the like, more preferably styrene. The presence of such aromatic vinyl unit reduces the positive birefringence of the glutarimide structure and hence can provide a (meth)acrylic resin film having additionally low retardations.

The glutarimide resin may contain only one kind of aromatic vinyl unit, or may contain a plurality of kinds of aromatic vinyl units different from each other in R⁷ or R⁸.

The content of the glutarimide unit in the glutarimide resin is preferably changed depending on, for example, the structure of R³. The content of the glutarimide unit is preferably 1 wt % to 80 wt %, more preferably 1 wt % to 70 wt %, still more preferably 1 wt % to 60 wt %, particularly preferably 1 wt % to 50 wt % with reference to all structural units of the glutarimide resin. As long as the content of the glutarimide unit falls within such range, a (meth)acrylic resin film having low retardations can be obtained.

The content of the aromatic vinyl unit in the glutarimide resin can be appropriately set in accordance with purposes and desired characteristics. The content of the aromatic vinyl unit may be 0 depending on applications. When the aromatic vinyl unit is incorporated, its content is preferably 10 wt % to 80 wt %, more preferably 20 wt % to 80 wt %, still more preferably 20 wt % to 60 wt %, particularly preferably 20 wt % to 50 wt % with reference to the glutarimide unit of the glutarimide resin. As long as the content of the aromatic vinyl unit falls within such range, a (meth)acrylic resin film having low retardations, and excellent in heat resistance and mechanical strength can be obtained.

The glutarimide resin may be further copolymerized with any structural unit other than the glutarimide unit, the (meth)acrylate unit, and the aromatic vinyl unit as required. Examples of the other structural unit include structural units constituted of: nitrile-based monomers such as acrylonitrile and methacrylonitrile; and maleimide-based monomers such as maleimide, N-methylmaleimide, N-phenylmaleimide, and N-cyclohexylmaleimide. Each of the other structural units may be directly copolymerized with the glutarimide resin, or may be subjected to graft copolymerization.

The (meth)acrylic resin film contains a UV absorbing agent. Any appropriate UV absorbing agent can be adopted as the UV absorbing agent as long as the desired characteristics are obtained. Representative examples of the UV absorbing agent include a triazine-based UV absorbing agent, a benzotriazole-based UV absorbing agent, a benzophenone-based UV absorbing agent, a cyanoacrylate-based UV absorbing agent, a benzoxazine-based UV absorbing agent, and an oxadiazole-based UV absorbing agent. Those UV absorbing agents may be used alone or in combination.

The content of the UV absorbing agent is preferably 0.1 part by weight to 5 parts by weight, more preferably 0.2 part by weight to 3 parts by weight with respect to 100 parts by weight of the (meth)acrylic resin. As long as the content of the UV absorbing agent falls within such range, UV light can be effectively absorbed and the transparency of the film at the time of the forming of the film does not reduce. When the content of the UV absorbing agent is less than 0.1 part by weight, a blocking effect on UV light tends to be insufficient. When the content of the UV absorbing agent is more than 5 parts by weight, the following tendency is observed: coloring becomes vigorous, the haze of the film after the forming increases, or the transparency deteriorates.

The (meth)acrylic resin film may contain any appropriate additive in accordance with purposes. Examples of the additive include hindered phenol-based, phosphorus-based, and sulfur-based antioxidants; stabilizers such as a light stabilizer, a weathering stabilizer, and a heat stabilizer; reinforcing materials such as glass fibers and carbon fibers; a near infrared ray absorbing agent; flame retardants such as tris(dibromopropyl) phosphate, triallyl phosphate, and antimony oxide; antistatic agents such as anionic, cationic, and nonionic surfactants; colorants such as an inorganic pigment, an organic pigment, and a dye; an organic filler and an inorganic filler; a resin modifier; an organic filling agent and an inorganic filling agent; a plasticizer; a lubricant; an antistatic agent; a flame retardant; and a retardation reducing agent. The kind, combination, content, and the like of the additive to be incorporated can be appropriately set in accordance with purposes and desired characteristics.

Although a method of producing the (meth)acrylic resin film is not particularly limited, for example, a (meth)acrylic resin, a UV absorbing agent, and another polymer, additive, or the like as required are thoroughly mixed by any appropriate mixing method to obtain a thermoplastic resin composition previously, and then the composition may be formed into a film. Alternatively, the (meth)acrylic resin, the UV absorbing agent, and the another polymer, additive, or the like as required are formed into separate solutions. After that, the solutions are mixed to obtain a homogenous mixed solution, and then, the solution may be formed into a film.

For producing the thermoplastic resin composition, for example, the above-mentioned film materials are preblended with any appropriate mixer such as an omni mixer, and then, the obtained mixture is extruded and kneaded. In this case, the mixer to be used for extrusion and kneading is not particularly limited, and for example, any appropriate mixer including an extruder such as a uniaxial extruder or a biaxial extruder and a pressure kneader may be used.

Available as a method for the film forming is any appropriate film forming method such as a solution casting method, a melt extrusion method, a calendering method, or a compression molding method. Of those, the melt extrusion method is preferred. The melt extrusion method can reduce a production cost and the load of a solvent on a global environment or working environment because the method does not involve using any solvent.

Examples of the melt extrusion method include a T-die method and an inflation method. The forming temperature is preferably 150 to 350° C., more preferably 200 to 300° C.

In the case of forming a film by the T-die method, a T-die is attached to a tip end of a known uniaxial extruder or a biaxial extruder, and a film extruded in a film shape is taken up to obtain a roll-shaped film. At this time, when a stretching force is applied in an extrusion direction while appropriately adjusting the temperature of a take-up roll, the film may be also stretched uniaxially. Further, when a film is stretched in a direction vertical to the extrusion direction, simultaneous biaxial stretching, sequential biaxial stretching, or the like may also be performed.

The (meth)acrylic resin film may be any of an unstretched film and a stretched film as long as the desired retardation is obtained. In the case where the film is a stretched film, the film may be any of a uniaxially stretched film and a biaxially stretched film. In the case where the film is a biaxially stretched film, the film may be any of a simultaneously biaxially stretched film and a sequentially biaxially stretched film.

The stretching temperature is preferably close to the glass transition temperature of a thermoplastic resin composition as a film raw material. Specifically, the stretching temperature falls within the range of preferably (glass transition temperature−30° C.) to (glass transition temperature+30° C.), more preferably (glass transition temperature−20° C.) to (glass transition temperature+20° C.). When the stretching temperature is less than (glass transition temperature−30° C.), the haze of the film to be obtained may increase, or the film may tear or crack to preclude the acquisition of a predetermined stretching ratio. In contrast, when the stretching temperature exceeds (glass transition temperature+30° C.), the following tendency is observed: the thickness unevenness of the film to be obtained enlarges, or its mechanical properties such as an elongation ratio, a tear propagation strength, and flex fatigue resistance cannot be sufficiently improved. Further, a trouble such as the sticking of the film to a roll tends to be liable to occur.

The stretching ratio is preferably 1.1 to 3 times, more preferably 1.3 to 2.5 times. As long as the stretching ratio falls within such range, the mechanical properties of the film such as an elongation ratio, a tear propagation strength, and flex fatigue resistance can be significantly improved. As a result, a film whose thickness unevenness is small, whose birefringence is substantially zero (therefore, retardations are small), and whose haze is small can be produced.

The (meth)acrylic resin film may be subjected to heat treatment (annealing) or the like after stretching treatment in order to stabilize its optical isotropy and mechanical characteristics. As the conditions of the heat treatment, any appropriate conditions may be adopted.

The thickness of the (meth)acrylic resin film is preferably 10 μm to 200 μm, more preferably 20 μm to 100 μm. When the thickness is less than 10 μm, strength may be decreased. When the thickness exceeds 200 μm, transparency may be decreased.

The wetting tension of the surface of the (meth)acrylic resin film is preferably 40 mN/m or more, more preferably 50 mN/m or more, still more preferably 55 mN/m or more. When the wetting tension of the surface is at least 40 mN/m or more, the adhesiveness between the (meth)acrylic resin film and the hard coat layer is further enhanced. In order to adjust the wetting tension of the surface, any appropriate surface treatment may be performed. Examples of the surface treatment include corona discharge treatment, plasma treatment, ozone spraying, UV-ray irradiation, flame treatment, and chemical treatment. Of those, corona discharge treatment and plasma treatment are preferably used.

C. Penetration Layer

As described above, the penetration layer is formed by the penetration of the composition for forming a hard coat layer into the (meth)acrylic resin film. In other words, the penetration layer can correspond to part of a region where the (meth)acrylic resin forming the (meth)acrylic resin film and the compound forming the hard coat layer are made compatible with each other.

It is preferred that in the penetration layer, the concentration of the (meth)acrylic resin forming the (meth)acrylic resin film continuously increase from a hard coat layer side to a base material layer side. This is because of the following reason. When the concentration of the (meth)acrylic resin continuously changes, i.e., no interface resulting from a change in concentration of the (meth)acrylic resin is formed, interface reflection can be suppressed and an optical laminate showing small interference unevenness can be obtained.

A lower limit for the thickness of the penetration layer is 1.2 μm, preferably 1.5 μm, more preferably 2 μm, still more preferably 3 μm. An upper limit for the thickness of the penetration layer is preferably (thickness of the (meth)acrylic resin film×70%) μm, more preferably (thickness of the (meth)acrylic resin film×40%) μm, still more preferably (thickness of the (meth)acrylic resin film×30%) μm, particularly preferably (thickness of the (meth)acrylic resin film×20%) μm. As long as the thickness of the penetration layer falls within such range, an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained. It should be noted that the thickness of the penetration layer can be measured on the basis of the reflection spectrum of the hard coat layer. Details about a method of measuring the thickness of the penetration layer are described later as an evaluation method in Examples.

D. Hard Coat Layer

As described above, the hard coat layer is formed by applying the composition for forming a hard coat layer onto the (meth)acrylic resin film. The composition for forming a hard coat layer contains a curable compound and inorganic nanoparticles. The curable compound can cure with, for example, heat, light (such as UV light), or an electron beam. The curable compound is preferably photocurable. The curable compound may be any one of a monomer, an oligomer, and a prepolymer. It should be noted that as described later, the inorganic nanoparticles can be covered with an organic compound (representatively an organic compound having a polymerizable unsaturated group). In the description, however, even in the case of such inorganic nanoparticles, the inorganic nanoparticles are not included in the “curable compound.”

The composition for forming a hard coat layer preferably contains a curable compound having 5 or more (meth)acryloyl groups. An upper limit for the number of (meth)acryloyl groups in the curable compound having 5 or more (meth)acryloyl groups is preferably 100. The use of the composition for forming a hard coat layer containing the curable compound having 5 or more (meth)acryloyl groups can provide a hard coat layer excellent in scratch resistance. It should be noted that the term “(meth)acryloyl” as used herein means methacryloyl and/or acryloyl.

Examples of the curable compound having 5 or more (meth)acryloyl groups include dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, caprolactone-modified dipentaerythritol hexa(meth)acrylate, and an oligomer or prepolymer thereof. These compounds may be used alone or in combination. It should be noted that the term “(meth)acrylate” as used herein means an acrylate and/or a methacrylate.

The curable compound having 5 or more (meth)acryloyl groups may be a urethane (meth)acrylate and/or an oligomer of the urethane (meth)acrylate. When the composition for forming a hard coat layer contains the urethane (meth)acrylate and/or the oligomer of the urethane (meth)acrylate, a hard coat layer excellent in flexibility and adhesiveness with the (meth)acrylic resin film can be formed. The urethane (meth)acrylate and the oligomer of the urethane (meth)acrylate more preferably have 9 or more functional groups. A hard coat layer excellent in scratch resistance can be formed by utilization of the composition for forming a hard coat layer containing a polyfunctional urethane (meth)acrylate and/or an oligomer of the urethane (meth)acrylate.

The urethane (meth)acrylate can be obtained by, for example, subjecting a hydroxy (meth)acrylate obtained from a (meth)acrylic acid or a (meth)acrylate and a polyol to a reaction with a diisocyanate. The urethane (meth)acrylate and the oligomer of the urethane (meth)acrylate may be used alone or in combination.

Examples of the (meth)acrylate include methyl (meth)acrylate, ethyl (meth)acrylate, isopropyl (meth)acrylate, butyl (meth)acrylate, and cyclohexyl (meth)acrylate.

Examples of the polyol include ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, diethylene glycol, dipropylene glycol, neopentyl glycol, 1,3-butanediol, 1,4-butanediol, 1,6-hexanediol, 1,9-nonanediol, 1,10-decanediol, 2,2,4-trimethyl-1,3-pentanediol, 3-methyl-1,5-pentanediol, neopentyl glycol hydroxypivalate, tricyclodecanedimethylol, 1,4-cyclohexanediol, Spiro glycol, hydrogenated bisphenol A, a bisphenol A-ethylene oxide adduct, a bisphenol A-propylene oxide adduct, trimethylolethane, trimethylolpropane, glycerin, 3-methylpentane-1,3,5-triol, pentaerythritol, dipentaerythritol, tripentaerythritol, and glucoses.

For example, various aromatic, aliphatic, or alicyclic diisocyanates may be used as the diisocyanate. Specific examples of the diisocyanate include tetramethylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, 2,4-trilene diisocyanate, 4,4-diphenyl diisocyanate, 1,5-naphthalene diisocyanate, 3,3-dimethyl-4,4-diphenyl diisocyanate, xylene diisocyanate, trimethylhexamethylene diisocyanate, 4,4-diphenylmethane diisocyanate, and a hydrogenated product thereof.

The weight-average molecular weight of the curable compound having 5 or more (meth)acryloyl groups is preferably 200 to 10,000, more preferably 500 to 5,000, still more preferably 1,000 to 5,000. When the oligomer of the urethane (meth)acrylate is used as the curable compound having 5 or more (meth)acryloyl groups, the weight-average molecular weight of the oligomer of the urethane (meth)acrylate is preferably 1,000 to 10,000, more preferably 1,000 to 5,000.

The content of the curable compound having 5 or more (meth)acryloyl groups is preferably 15 wt % to 100 wt %, more preferably 20 wt % to 100 wt %, still more preferably 40 wt % to 100 wt %, particularly preferably 40 wt % to 70 wt % with respect to all curable compounds in the composition for forming a hard coat layer. As long as the content falls within such range, an optical laminate additionally excellent in scratch resistance can be obtained. In addition, an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained.

When the urethane (meth)acrylate and/or the oligomer of the urethane (meth)acrylate are each/is used as the curable compound having 5 or more (meth)acryloyl groups, the total content of the urethane (meth)acrylate and the oligomer of the urethane (meth)acrylate is preferably 20 wt % to 100 wt %, more preferably 20 wt % to 70 wt % with respect to all curable compounds in the composition for forming a hard coat layer. As long as the total content falls within such range, a hard coat layer additionally excellent in scratch resistance, and excellent in balance among hardness, flexibility, and adhesiveness can be formed. In addition, an optical laminate that has suppressed interference unevenness can be obtained.

The composition for forming a hard coat layer may contain a curable compound having 2 to 4 (meth)acryloyl groups. As long as the composition contains the curable compound having 2 to 4 (meth)acryloyl groups, an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained.

Examples of the curable compound having 2 to 4 (meth)acryloyl groups include a polyethylene glycol diacrylate, tricyclodecanedimethanol diacrylate, 1,10-decanediol diacrylate, 1,6-hexanediol diacrylate, 1,9-nonanediol diacrylate, dipropylene glycol diacrylate, polypropylene glycol diacrylate, pentaerythritol di(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, and isocyanuric acid triacrylate. In addition, a urethane (meth)acrylate and/or an oligomer of the urethane (meth)acrylate may be used as the curable compound having 2 to 4 (meth)acryloyl groups.

The weight-average molecular weight of the curable compound having 2 to 4 (meth)acryloyl groups is preferably 200 to 1,500, more preferably 200 to 1,000. As long as the composition for forming a hard coat layer contains the curable compound having 2 to 4 (meth)acryloyl groups and having a weight-average molecular weight of 1,500 or less, an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained.

The curable compound having 2 to 4 (meth)acryloyl groups preferably has a hydroxyl group. As long as the composition for forming a hard coat layer contains such curable compound, a heating temperature at the time of the formation of the hard coat layer can be set to an additionally low temperature and a heating time at the time can be set to an additionally short time, and hence an optical laminate whose deformation due to heating has been suppressed can be efficiently produced. In addition, an optical laminate excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer can be obtained. The curable compound having a hydroxyl group and 2 to 4 (meth)acryloyl groups is, for example, pentaerythritol tri(meth)acrylate.

When the composition for forming a hard coat layer contains the curable compound having 2 to 4 (meth)acryloyl groups, the content of the curable compound having 2 to 4 (meth)acryloyl groups is preferably 85 wt % or less, more preferably 60 wt % or less with respect to all curable compounds in the composition for forming a hard coat layer. When the content of the curable compound having 2 to 4 (meth)acryloyl groups is more than 85 wt %, desired hardness and desired scratch resistance may not be obtained.

The composition for forming a hard coat layer may contain a monofunctional monomer as a curable compound. As long as the composition contains the monofunctional monomer, an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained because the monofunctional monomer easily penetrates into the (meth)acrylic resin film. When the composition for forming a hard coat layer contains the monofunctional monomer, the content of the monofunctional monomer is preferably 40 wt % or less, more preferably 20 wt % or less with respect to all curable compounds in the composition for forming a hard coat layer. When the content of the monofunctional monomer is more than 40 wt %, desired hardness and desired scratch resistance may not be obtained.

The monofunctional monomer preferably has a weight-average molecular weight of 500 or less. Such monofunctional monomer easily penetrates and diffuses into the (meth)acrylic resin film. Examples of such monofunctional monomer include ethoxylated o-phenylphenol (meth)acrylate, methoxy polyethylene glycol (meth)acrylate, phenoxy polyethylene glycol (meth)acrylate, 2-ethylhexyl acrylate, lauryl acrylate, isooctyl acrylate, isostearyl acrylate, cyclohexyl acrylate, isobornyl acrylate, benzyl acrylate, 2-hydroxy-3-phenoxy acrylate, acryloylmorpholine, 2-hydroxyethyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, dimethylaminopropyl acrylamide, and N-(2-hydroxyethyl) (meth)acrylamide.

The monofunctional monomer preferably has a hydroxyl group. In the case of such monofunctional monomer, the heating temperature at the time of the formation of the hard coat layer can be set to an additionally low temperature and the heating time at the time can be set to an additionally short time, and hence an optical laminate whose deformation due to heating has been suppressed can be efficiently produced. In addition, as long as the composition for forming a hard coat layer contains the monofunctional monomer having a hydroxyl group, an optical laminate excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer can be obtained. Examples of such monofunctional monomer include: hydroxyalkyl (meth)acrylates such as 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-hydroxy-3-phenoxy acrylate, and 1,4-cyclohexanemethanol monoacrylate; and N-(2-hydroxyalkyl) (meth)acrylamides such as N-(2-hydroxyethyl) (meth)acrylamide and N-methylol (meth)acrylamide. Of those, 4-hydroxybutyl acrylate and N-(2-hydroxyethyl)acrylamide are preferred.

The boiling point of the monofunctional monomer is preferably higher than the heating temperature (described later) of an application layer at the time of the formation of the hard coat layer. The boiling point of the monofunctional monomer is, for example, preferably 150° C. or more, more preferably 180° C. or more, particularly preferably 200° C. or more. As long as the boiling point falls within such range, the monofunctional monomer can be prevented from volatilizing owing to heating at the time of the formation of the hard coat layer and hence the monofunctional monomer can be caused to penetrate into the (meth)acrylic resin film sufficiently.

The composition for forming a hard coat layer contains inorganic nanoparticles. When the hard coat layer is formed by applying the composition for forming a hard coat layer containing the inorganic nanoparticles, the inorganic nanoparticles can prevent a component in the (meth)acrylic resin film that has been eluted into the composition for forming a hard coat layer (representatively a resin component in the (meth)acrylic resin film) from diffusing to the air interface of the hard coat layer at the time of the formation of the hard coat layer. As a result, an optical laminate excellent in scratch resistance can be obtained.

Examples of the inorganic nanoparticle include fine particles of metal oxide such as silicon oxide (silica), titanium oxide, aluminum oxide (alumina), zinc oxide, tin oxide, or zirconium oxide (zirconia). These particles may be used alone or in combination. Of those, fine particles of silicon oxide (silica), aluminum oxide (alumina), and zirconium oxide (zirconia) are preferred, and silicon oxide (silica) is more preferred because the shrinkage on curing of the composition for forming a hard coat layer may be reduced and the hard coat layer may have high hardness.

At least part of the surface of each of the inorganic nanoparticles is preferably covered with an organic compound. The inorganic nanoparticles at least part of the surface of each of which is covered with the organic compound are excellent in dispersibility in the composition for forming a hard coat layer, and hence the inorganic nanoparticles can effectively prevent the diffusion of the component in the (meth)acrylic resin film into the composition for forming a hard coat layer (which results in diffusion into the hard coat layer) and can provide a hard coat layer additionally excellent in scratch resistance. In addition, as long as the inorganic nanoparticles are excellent in dispersibility, the light scattering of the hard coat layer and a reduction in transmittance are prevented, and hence an optical laminate having excellent transparency can be obtained.

An aspect in which at least part of the surface of each of the inorganic nanoparticles is covered with the organic compound is, for example, an aspect in which the inorganic nanoparticles are metal oxide fine particles and the organic compound is bonded to at least part of the surface of each of the inorganic nanoparticles (metal oxide fine particles) by the reaction of the organic compound with a hydroxyl group present on the surface of each of the metal oxide fine particles, an aspect in which the organic compound is caused to adhere to a hydroxyl group present on the surface of each of the inorganic nanoparticles (metal oxide fine particles) by an interaction such as a hydrogen bond, or an aspect in which a polymer particle contains one or more inorganic nanoparticles in itself.

The organic compound covering the inorganic nanoparticles preferably has a functional group that can be chemically bonded to a functional group present on the surface of each of the inorganic nanoparticles under a dispersion condition. Examples of such functional group include an acryloyl group, a methacryloyl group, a vinyl group, a propenyl group, a butadienyl group, a styryl group, an ethynyl group, a cinnamoyl group, a maleate group, a acrylamide group, a carboxyl group, a phosphoric acid group, an acid anhydride group, an acid chloride group, an acid amide group, an ester group, an imino group, a nitryl group, an isonitryl group, a hydroxyl group, a thiol group, an epoxy group, a primary amino group, a secondary amino group, a tertiary amino group, a Si—OH group, and a hydrolyzable residue of silane. The functional group contained in the organic compound covering the inorganic nanoparticles is preferably capable of binding to a functional group present on the surface of each of the inorganic nanoparticles with a covalent bond, an ionic bond, a coordinate bond, or a hydrogen bond, more preferably a covalent bond, an ionic bond, or a coordinate bond. The organic compound covering the inorganic nanoparticles may be used alone or in combination.

The organic compound covering the inorganic nanoparticles more preferably has a polymerizable unsaturated group. When the polymerizable unsaturated group reacts with the curable compound in the composition for forming a hard coat layer to cure the compound, the hardness of the hard coat layer can be improved. For example, an acryloyl group, a methacryloyl group, a vinyl group, a propenyl group, a butadienyl group, a styryl group, an ethynyl group, a cinnamoyl group, a maleate group, an acrylamide group are preferred as the polymerizable unsaturated group. It is also preferred that the polymerizable unsaturated group is a photosensitive group.

Examples of the organic compound covering the inorganic nanoparticles include: polysiloxanes such as a polydimethylsiloxane, a polydiphenylsiloxane, a polymethylphenylsiloxane, and a polymethyl hydrogen siloxane; and silane coupling agents such as γ-glycidyloxypropyltrimethoxysilane (GPTS), γ-glycidyloxypropyldimethylchlorosilane, 3-aminopropyltrimethoxysilane (APTS), 3-aminopropyltriethoxysilane (APTES), N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, N—[N′-(2′-aminoethyl)-2-aminoethyl]-3-aminopropyltrimethoxysilane, hydroxymethyltrimethoxysilane, 2-[methoxy(polyethyleneoxy)propyl]trimethoxysilane, bis-(hydroxyethyl)-3-aminopropyltriethoxysilane, N-hydroxyethyl-N-methylaminopropyltriethoxysilane, 3-(meth)acryloxypropyltriethoxysilane, 3-(meth)acryloxypropyltrimethoxysilane, CH₂═CHSi(OOCCH₃)₃, CH₂═CHSiCl₃, CH₂═CHSi(OC₂H₅)₃, CH₂═CH—Si(OC₂H₄OCH₃)₃, CH₂═CH—CH₂—Si(OC₂H₅)₃, and CH₂═CH—CH₂—Si(OOCCH₃)₃. A silane coupling agent is preferably used as the organic compound covering the inorganic nanoparticles because the silane coupling agent has sufficient reactivity with a metal oxide, and shows less yellowing.

The inorganic nanoparticles covered with the organic compound having a photosensitive group are obtained by, for example, treating the inorganic nanoparticles with a silane coupling agent having a photosensitive group. Examples of the silane coupling agent having a photosensitive group include CH₂═CHSi(OOCCH₃)₃, CH₂═CHSiCl₃, CH₂═CHSi(OC₂H₅)₃, CH₂═CH—Si(OC₂H₄OCH₃)₃, CH₂═CH—CH₂—Si(OC₂H₅)₃, and CH₂═CH—CH₂—Si(OOCCH₃)₃. A method of producing the silane coupling agent having a photosensitive group is described in, for example, Japanese Patent Application Laid-open No. Hei 9-100111. The silane coupling agent having a photosensitive group can be obtained by, for example, (i) an addition reaction among a mercaptoalkoxysilane, a polyisocyanate compound, and an active hydrogen group-containing polymerizable unsaturated compound capable of reacting with an isocyanate group, (ii) a reaction between a compound having an alkoxysilyl group and an isocyanate group in a molecule thereof, and an active hydrogen group-containing polymerizable unsaturated compound, or (iii) an addition reaction between a compound having a polymerizable unsaturated group and an isocyanate group in a molecule thereof, and a mercaptoalkoxysilane.

Any appropriate shape can be adopted as the shape of each of the inorganic nanoparticles. The shape of each of the inorganic nanoparticles can be a spherical shape, a rectangular parallelopiped shape, a needle shape, or a plate shape.

The weight-average particle diameter of the inorganic nanoparticles is preferably 100 nm or less, more preferably 1 nm to 50 nm, still more preferably 1 nm to 20 nm. As long as the weight-average particle diameter falls within such range, the light scattering of the hard coat layer can be prevented, a reduction in transmittance can be prevented, coloring can be prevented, and excellent transparency can be secured. The weight-average particle diameter of the inorganic nanoparticles can be measured by, for example, a Coulter counter method.

The content of the inorganic nanoparticles is 1.5 wt % to 50 wt % with respect to the total of the curable compound and inorganic nanoparticles in the composition for forming a hard coat layer. As long as the content falls within such range, the diffusion of the component in the (meth)acrylic resin film into the composition for forming a hard coat layer (which results in diffusion into the hard coat layer) can be effectively prevented and a hard coat layer excellent in scratch resistance can be obtained. The content of the inorganic nanoparticles is preferably 1.5 wt % to 30 wt %, more preferably 8 wt % to 30 wt %, still more preferably 20 wt % to 30 wt % with respect to the total of the curable compound and inorganic nanoparticles in the composition for forming a hard coat layer. As long as the content falls within such range, the inorganic nanoparticles can be prevented from forming the so-called particle layer and hence an optical laminate showing small interference unevenness can be obtained.

The composition for forming a hard coat layer preferably contains any appropriate photopolymerization initiator. Examples of the photopolymerization initiator include 2,2-dimethoxy-2-phenylacetophenone, acetophenone, benzophenone, xanthone, 3-methylacetophenone, 4-chlorobenzophenone, 4,4′-dimethoxybenzophenone, benzoin propyl ether, benzyl dimethyl ketal, N,N,N′,N′-tetramethyl-4,4′-diaminobenzophenone, 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one, and a thioxanthone-based compound.

In one embodiment, the surface of the hard coat layer opposite to the base material layer has an uneven structure. When the surface of the hard coat layer is of an uneven structure, antiglare property can be imparted to the optical laminate. A method of forming such uneven structure is, for example, a method involving incorporating fine particles into the composition for forming a hard coat layer. The fine particles may be inorganic fine particles or may be organic fine particles. Examples of the inorganic fine particle include a silicon oxide fine particle, a titanium oxide fine particle, an aluminum oxide fine particle, a zinc oxide fine particle, a tin oxide fine particle, a calcium carbonate fine particle, a valium sulfate fine particle, a talc fine particle, a kaolin fine particle, and a calcium sulfate fine particle. Examples of the organic fine particle include a polymethyl methacrylate resin powder (PMMA fine particle), a silicone resin powder, a polystyrene resin powder, a polycarbonate resin powder, an acryl styrene resin powder, a benzoguanamine resin powder, a melamine resin powder, a polyolefin resin powder, a polyester resin powder, a polyamide resin powder, a polyimide resin powder, and a polyethylene fluoride resin powder. Those fine particles may be used alone or in combination.

Any appropriate shape can be adopted as the shape of each of the fine particles. The shape is preferably a substantially spherical shape and is more preferably a substantially spherical shape having an aspect ratio of 1.5 or less. The weight-average particle diameter of the fine particles is preferably 1 μm to 30 μm, more preferably 2 μm to 20 μm. The weight-average particle diameter of the fine particles can be measured by, for example, a Coulter counter method.

When the composition for forming a hard coat layer contains the fine particles, the content of the fine particles is preferably 1 wt % to 60 wt %, more preferably 2 wt % to 50 wt % with respect to all curable compounds in the composition for forming a hard coat layer.

The composition for forming a hard coat layer can further contain any appropriate additive. Examples of the additive include a leveling agent, an antiblocking agent, a dispersion stabilizer, a thixotropic agent, an antioxidant, a UV absorbing agent, an antifoaming agent, a tackifier, a dispersant, a surfactant, a catalyst, a filler, a lubricant, and an antistatic agent.

For example, fluorine- or silicone-based leveling agents are given as the leveling agent, and the leveling agent is preferably a silicone-based leveling agent. Examples of the silicone-based leveling agent include a reactive silicone, a polydimethylsiloxane, a polyether-modified polydimethylsiloxane, and a polymethylalkylsiloxane. Of those, a reactive silicone is preferred. When the reactive silicone is added, sliding property is imparted to the surface of the hard coat layer and its scratch resistance continues over a long time period. The content of the leveling agent is preferably 5 wt % or less, more preferably 0.01 wt % to 5 wt % with respect to the total amount of the monomer, oligomer, and prepolymer in the composition for forming a hard coat layer.

The composition for forming a hard coat layer may or may not include a solvent. Examples of the solvent include dibutyl ether, dimethoxymethane, dimethoxyethane, diethoxyethane, propylene oxide, 1,4-dioxane, 1,3-dioxolane, 1,3,5-trioxane, tetrahydrofuran, acetone, methyl ethyl ketone (MEK), diethyl ketone, dipropyl ketone, diisobutyl ketone, cyclopentanone (CPN), cyclohexanone, methylcyclohexanone, ethyl formate, propyl formate, n-pentyl formate, methyl acetate, ethyl acetate, methyl propionate, ethyl propionate, n-pentyl acetate, acetyl acetone, diacetone alcohol, methyl acetoacetate, ethyl acetoacetate, methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2-methyl-2-butanol, cyclohexanol, isopropyl alcohol (IPA), isobutyl acetate, methyl isobutyl ketone (MIBK), 2-octanone, 2-pentanone, 2-hexanone, 2-heptanone, 3-heptanone, ethylene glycol monoethyl ether acetate, ethylene glycol monoethyl ether, ethylene glycol monobutyl ether, ethylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, and propylene glycol monomethyl ether. Those solvents may be used alone or in combination.

According to the present invention, even when a composition for forming a hard coat layer free of any solvent or a composition for forming a hard coat layer containing only a poor solvent for the formation materials for the (meth)acrylic resin film as a solvent is used, the composition for forming a hard coat layer penetrates into the (meth)acrylic resin film and hence a penetration layer having a desired thickness can be formed.

The thickness of the hard coat layer is preferably 3 μm or more, more preferably 5 μm or more, still more preferably 7 μm to 20 μm. As long as the thickness falls within such range, an optical laminate excellent in scratch resistance can be obtained. In addition, the optical laminate of the present invention is excellent in scratch resistance even when the thickness of the hard coat layer is reduced because the diffusion of the component in the (meth)acrylic resin film into the hard coat layer (composition for forming a hard coat layer) is suppressed as described above.

E. Other Layers

In the optical laminate of the present invention, any appropriate other layer can be placed outside the hard coat layer as required. Representative examples thereof include an antireflection layer and an antiglare layer. An antireflection layer and antiglare layer typically used in the industry can be adopted as the antireflection layer and the antiglare layer.

F. Method of Producing Optical Laminate

A method of producing the optical laminate of the present invention includes: applying the composition for forming a hard coat layer onto the (meth)acrylic resin film to form an application layer; and heating the application layer. The hard coat layer is preferably formed by subjecting the application layer after the heating to a curing treatment.

As a method of applying the composition for forming a hard coat layer, any appropriate method may be adopted. Examples of the method include a bar coating method, a roll coating method, a gravure coating method, a rod coating method, a slot orifice coating method, a curtain coating method, a fountain coating method, and a comma coating method.

The heating temperature of the application layer can be set to an appropriate temperature in accordance with the composition of the composition for forming a hard coat layer, and is preferably set to a temperature equal to or less than the glass transition temperature of the resin in the (meth)acrylic resin film. When the heating is performed at a temperature equal to or less than the glass transition temperature of the resin in the (meth)acrylic resin film, an optical laminate whose deformation due to heating has been suppressed can be obtained. The heating temperature of the application layer is, for example, 80° C. to 140° C. When the heating is performed at a temperature in such range, the monomer, oligomer, and/or prepolymer in the composition for forming a hard coat layer each penetrate and diffuse/penetrates and diffuses into the (meth)acrylic resin film favorably. The penetration layer described in the section C is formed of the composition for forming a hard coat layer that has penetrated through the heating and the subsequent curing treatment, and the formation materials for the (meth)acrylic resin film. As a result, an optical laminate that is excellent in adhesiveness between the (meth)acrylic resin film and the hard coat layer, and that has suppressed interference unevenness can be obtained. In addition, the heating temperature of the application layer can be set to a lower temperature as the molecular weight of a compound in the composition for forming a hard coat layer reduces. In addition, the heating temperature of the application layer can be set to a low temperature (e.g., 80° C. to 100° C.) by incorporating a monofunctional monomer into the composition for forming a hard coat layer, and the temperature can be set to a lower temperature as the content of the monofunctional monomer increases. It should be noted that when the composition for forming a hard coat layer contains a solvent, the applied composition for forming a hard coat layer can be dried by the heating.

Any appropriate curing treatment can be adopted as the curing treatment. The curing treatment is representatively performed by UV irradiation. The cumulative light quantity of the UV irradiation is preferably 200 mJ to 400 mJ.

EXAMPLES

Hereinafter, the present invention is specifically described by way of examples but the present invention is not limited by these examples. Evaluation methods in the examples are as described below. In addition, in the examples, the terms “part (s)” and “%” refer to “part (s) by weight” and “wt %,” respectively unless otherwise stated.

(1) Scratch Resistance

An optical laminate obtained in each of Examples and Comparative Examples was cut into a piece measuring 11 mm wide by 100 mm long, and was then mounted on a glass plate with its base material layer directed downward. Next, a steel wool #0000 attached to a section of a cylinder having a diameter of 11 mm was reciprocated 10 times on the surface of the optical laminate on a hard coat layer side under a load of 400 g at 100 mm/sec. After that, the surface on the hard coat layer side was visually observed and evaluated by the following criteria.

In addition, the same evaluation as the foregoing was performed except that the load was changed to 600 g.

4: The surface has no flaw.

3: The surface is slightly flawed.

2: Fine flaws remain on the surface.

1: The surface has remarkable flaws.

(2) Pencil Hardness

The surface of the optical laminate obtained in each of Examples and Comparative Examples on the hard coat layer side was evaluated for its pencil hardness in conformity with JIS K 5400 (load: 500 g)

(3) Adhesiveness of Hard Coat Layer

The adhesiveness of the hard coat layer with the base material film was evaluated in conformity with the crosscut peel test of JIS K-5400 (crosscut number: 100).

(4) Interference Unevenness

A black acrylic plate (manufactured by MITSUBISHI RAYON CO., LTD. and having a thickness of 2 mm) was attached to the base material film side of the optical laminate obtained in each of Examples and Comparative Examples through an acrylic pressure-sensitive adhesive. After that, under a three-band fluorescent lamp, interference unevenness was visually observed and evaluated by the following criteria.

4: No interference unevenness occurs.

3: The occurrence of interference unevenness is slightly observed but no problem arises in practical use.

2: The occurrence of interference unevenness is considerably observed.

1: The occurrence of interference unevenness is remarkably observed.

(5) Thickness of Penetration Layer

A black acrylic plate (manufactured by MITSUBISHI RAYON CO., LTD. and having a thickness of 2 mm) was attached to the base material layer side of an optical laminate obtained in each of Examples and Comparative Examples through an acrylic pressure-sensitive adhesive having a thickness of 20 μm. Next, the reflection spectrum of the hard coat layer was measured with an instantaneous multi-spot photometry system (manufactured by Otsuka Electronics Co., Ltd., trade name: MCPD3700) under the following conditions, and then the thickness of (hard coat layer+penetration layer) was evaluated from the peak position of an FFT spectrum. It should be noted that the refractive index was measured with an Abbe refractometer manufactured by ATAGO CO., LTD. (trade name: DR-M2/1550) by selecting monobromonaphthalene as an intermediate liquid.

Conditions for measurement of reflection spectrum Reference: A mirror Algorithm: An FFT method Calculation wavelength: 450 nm to 850 nm Detection conditions Exposure time: 20 ms Lamp gain: Normal Cumulative number: 10 times FFT method Range of thickness value: 2 μm to 15 μm Thickness resolution: 24 nm

In addition, the thickness of the hard coat layer was evaluated by the reflection spectrum measurement for the following laminate (R).

Laminate (R): The laminate was obtained in the same manner as in Example 6 except that a PET base material (manufactured by Toray Industries, Inc., trade name: U48-3, refractive index: 1.60) was used as a base material film and the heating temperature of an application layer was set to 60° C.

It should be noted that the thickness of only the hard coat layer is measured from the peak position of the FFT spectrum obtained from the laminate (R) because a composition for forming a hard coat layer does not penetrate into the PET base material to be used in each of these laminates. As a result of the evaluation, the thickness of the hard coat layer was 5.3 μm.

A positive value calculated from the equation “(thickness of (hard coat layer+penetration layer))−(thickness of (hard coat layer))” was defined as the thickness of the penetration layer. It should be noted that when only a negative value is calculated from the definitional equation, it can be judged that no penetration layer is formed and the negative value can be judged to be the thickness of a layer formed by the elution of the formation materials for the base material film into the hard coat layer. In addition, when two peaks of the FFT spectrum are detected, and two values that are positive and negative are calculated from the definitional equation, the positive value can be judged to be the thickness of the penetration layer.

<Production Example 1> Production of Base Material Film A

100 Parts by weight of an imidized MS resin described in Production Example 1 of Japanese Patent Application Laid-open No. 2010-284840 and 0.62 part by weight of a triazine-based UV absorbing agent (manufactured by ADEKA CORPORATION, trade name: T-712) were mixed with a biaxial kneader at 220° C. to produce a resin pellet. The resultant resin pellet was dried at 100.5 kPa and 100° C. for 12 hours, and was then extruded from the T-die of a uniaxial extruder at a die temperature of 270° C. to be formed into a film shape (having a thickness of 160 μm). Further, the film was stretched in its conveyance direction under an atmosphere at 150° C. (to have a thickness of 80 μm). Next, the film was stretched in a direction perpendicular to the film conveyance direction under an atmosphere at 150° C. to provide a base material film A ((meth)acrylic resin film) having a thickness of 40 μm. The resultant base material film A had a transmittance for light having a wavelength of 380 nm of 8.5%, an in-plane retardation Re of 0.4 nm, and a thickness direction retardation Rth of 0.78 nm. In addition, the resultant base material film A had a moisture permeability of 61 g/m²·24 hr. It should be noted that the light transmittance was obtained by measuring a transmittance spectrum in the wavelength range of 200 nm to 800 nm with a spectrophotometer manufactured by Hitachi High-Technologies Corporation (apparatus name; U-4100) and reading a transmittance at a wavelength of 380 nm. In addition, the retardation values were each measured with a product available under the trade name “KOBRA21-ADH” from Oji Scientific Instruments at a wavelength of 590 nm and 23° C. The moisture permeability was measured by a method in conformity with JIS K0208 under the conditions of a temperature of 40° C. and a relative humidity of 92%.

<Production Example 2> Production of Zirconia Dispersion Liquid

100 Parts of zirconia beads (manufactured by TOSOH CORPORATION), 10 parts of zirconia particles (manufactured by Daiichi Kigenso Kagaku Kogyo Co., Ltd., trade name: UEP-100), 5 parts of a phosphate dispersant (manufactured by BYK-Chemie Japan, DISPERBYK-142), and 15 parts of methyl isobutyl ketone were mixed, and then the mixture was subjected to a dispersion treatment with a disperser (manufactured by LAU, trade name: Disperser DAS H200-K) for 3 hours to provide a zirconia dispersion liquid (zirconia: 33%).

Example 1

100 Parts of a UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806, solid content: 80%, solvent: butyl acetate), 5 parts of an organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907) were mixed, and then the mixture was diluted with methyl isobutyl ketone so that a solid content concentration became 50%. Thus, a composition for forming a hard coat layer was prepared. It should be noted that the organic-inorganic hybrid resin (Opstar Z7540) contains (1-1) dipentaerythritol hexaacrylate, (1-2) an isophorone diisocyanate-based polyurethane acrylate, and (2) silica fine particles each having a surface covered with an organic compound having a polymerizable unsaturated group (having a weight-average particle diameter of 100 nm or less) at a weight ratio “(1-1):(1-2):(2)” of 66:34:150. In addition, curable compounds in the UV-curable resin (UNIDIC 17-806) and their contents are as described below.

Isocyanuric acid triacrylate 13 parts Pentaerythritol triacrylate 16 parts Dipentaerythritol hexaacrylate 62 parts Isophorone diisocyanate-based polyurethane acrylate  9 parts

The resultant composition for forming a hard coat layer was applied onto the base material film A obtained in Production Example 1 to form an application layer, and then the application layer was heated at 110° C. for 1 minute. The application layer after the heating was cured by irradiating the application layer with UV light having a cumulative light quantity of 300 mJ/cm² from a high-pressure mercury lamp, whereby a base material layer, a hard coat layer, and a penetration layer were formed. Thus, an optical laminate was obtained. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 2

An optical laminate was obtained in the same manner as in Example 1 except that 10 parts of a dispersion liquid containing 30% of alumina having a surface covered with an organic compound (manufactured by BYK-Chemie Japan, NANOBYK-3610, solid content: 37 wt %, solvent: propylene glycol monomethyl ether acetate) were used instead of 5 parts of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540). The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 3

An optical laminate was obtained in the same manner as in Example 1 except that 10 parts of the zirconia dispersion liquid obtained in Production Example 2 were used instead of 5 parts of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540). The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 4

An optical laminate was obtained in the same manner as in Example 1 except that: dipentaerythritol hexaacrylate (manufactured by Shin Nakamura Chemical Co., Ltd., trade name: A-DPH) was used instead of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 6 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 5

An optical laminate was obtained in the same manner as in Example 1 except that: dipentaerythritol hexaacrylate (manufactured by Shin Nakamura Chemical Co., Ltd., trade name: A-DPH) was used instead of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 125 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 6

An optical laminate was obtained in the same manner as in Example 1 except that: a mixture of 60 parts of a hexafunctional urethane acrylic oligomer, 30 parts of pentaerythritol tetraacrylate, and 10 parts of pentaerythritol triacrylate (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 6 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 7

An optical laminate was obtained in the same manner as in Example 1 except that: a mixture of 60 parts of a hexafunctional urethane acrylic oligomer, 30 parts of pentaerythritol tetraacrylate, and 10 parts of pentaerythritol triacrylate (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 125 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 8

An optical laminate was obtained in the same manner as in Example 1 except that: a mixture of 60 parts of a hexafunctional urethane acrylic oligomer, 30 parts of pentaerythritol tetraacrylate, and 10 parts of pentaerythritol triacrylate (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 750 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 9

An optical laminate was obtained in the same manner as in Example 1 except that: a mixture of 60 parts of a hexafunctional urethane acrylic oligomer, 30 parts of pentaerythritol tetraacrylate, and 10 parts of pentaerythritol triacrylate (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and 10 parts of a dispersion liquid containing 30% of alumina having a surface covered with an organic compound (manufactured by BYK-Chemie Japan, NANOBYK-3610) were used instead of 5 parts of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540). The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 10

An optical laminate was obtained in the same manner as in Example 1 except that: a mixture of 60 parts of a hexafunctional urethane acrylic oligomer, 30 parts of pentaerythritol tetraacrylate, and 10 parts of pentaerythritol triacrylate (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and 10 parts of the zirconia dispersion liquid obtained in Production Example 2 were used instead of 5 parts of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540). The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

Example 11

An optical laminate was obtained in the same manner as in Example 1 except that: 100 parts of a mixture of pentaerythritol triacrylate (manufactured by Osaka Organic Chemical Industry Ltd., trade name: VISCOAT #300) and dipentaerythritol hexaacrylate (manufactured by Shin Nakamura Chemical Co., Ltd., trade name: A-DPH) (weight mixing ratio “VISCOAT #300:A-DPH”=8:2) were used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 36 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 1 below shows the results.

TABLE 1 Heating Scratch Adhesiveness Thickness Composition for forming hard coat layer temperature resistance Pencil (number of peeled Interference of penetration Curable compound Inorganic nanoparticles Content (wt %) (° C.) 400 g 600 g hardness crosscuts) unevenness layer (μm) Example 1 UNIDIC 17-806 Opstar Z7540 2.0 110 4 3 2H 0 4 1.5 Isocyanuric acid Dipentaerythritol Silica triacrylate/pentaerythritol hexaacrylate/isophorone triacrylate/dipentaerythritol diisocyanate-based hexaacrylate/isophorone polyurethane diisocyanate-based acrylate polyurethane acrylate Example 2 UNIDIC 17-806 NANOBYK-3610 3.6 110 3 3 2H 0 4 1.7 Isocyanuric acid Alumina triacrylate/pentaerythritol triacrylate/dipentaerythritol hexaacrylate/isophorone diisocyanate-based polyurethane acrylate Example 3 UNIDIC 17-806 Production Example 2 4.0 110 3 2 2H 0 4 2.0 Isocyanuric acid Zirconia triacrylate/pentaerythritol triacrylate/dipentaerythritol hexaacrylate/isophorone diisocyanate-based polyurethane acrylate Example 4 A-DPH Opstar Z7540 2.0 110 4 3 2H 0 4 3.0 Dipentaerythritol Dipentaerythritol Silica hexaacrylate hexaacrylate/isophorone diisocyanate-based polyurethane acrylate Example 5 A-DPH Opstar Z7540 24.7 110 4 4 3H 0 4 4.7 Dipentaerythritol Dipentaerythritol Silica hexaacrylate hexaacrylate/isophorone diisocyanate-based polyurethane acrylate Example 6 UV-7600B Opstar Z7540 2.0 110 4 3 2H 0 4 4.2 Hexafunctional urethane Dipentaerythritol Silica acrylic hexaacrylate/isophorone oligomer/pentaerythritol diisocyanate-based tetraacrylate/pentaerythritol polyurethane triacrylate acrylate Example 7 UV-7600B Opstar Z7540 24.7 110 4 4 3H 0 4 3.7 Hexafunctional urethane Dipentaerythritol Silica acrylic hexaacrylate/isophorone oligomer/pentaerythritol diisocyanate-based tetraacrylate/pentaerythritol polyurethane triacrylate acrylate Example 8 UV-7600B Opstar Z7540 48.5 110 4 4 3H 0 1 2.5 Hexafunctional urethane Dipentaerythritol Silica acrylic hexaacrylate/isophorone oligomer/pentaerythritol diisocyanate-based tetraacrylate/pentaerythritol polyurethane triacrylate acrylate Example 9 UV-7600B NANOBYK-3610 2.9 110 3 3 2H 0 4 2.3 Hexafunctional urethane Alumina acrylic oligomer/pentaerythritol tetraacrylate/pentaerythritol triacrylate Example 10 UV-7600B Production Example 2 3.2 110 3 3 2H 0 4 2.3 Hexafunctional urethane Zirconia acrylic oligomer/pentaerythritol tetraacrylate/pentaerythritol triacrylate Example 11 VISCOAT #300/A-DPH Opstar Z7540 10.1 110 3 3 2H 0 4 5.5 Pentaerythritol Dipentaerythritol Silica triacrylate/dipentaerythritol hexaacrylate/isophorone hexaacrylate diisocyanate-based polyurethane acrylate

Example 12

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 100 parts of a UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806, solid content: 80%, solvent: butyl acetate), 20 parts of 4-hydroxybutyl acrylate (4-HBA) (manufactured by Osaka Organic Chemical Industry Ltd.), 125 parts of an organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

Example 13

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 70 parts of a dipentaerythritol hexaacrylate (manufactured by Shin-Nakamura Chemical Co., Ltd., trade name: A-DPH), 30 parts of 4-hydroxybutyl acrylate (4-HBA) (manufactured by Osaka Organic Chemical Industry Ltd.), 125 parts of an organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

Example 14

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 80 parts of the “SHIKOH UV-7600B” manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., 20 parts of 4-hydroxybutyl acrylate (4-HBA) (manufactured by Osaka Organic Chemical Industry Ltd.), 6 parts of an organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

Example 15

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 70 parts of the “SHIKOH UV-7600B” manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., 30 parts of 4-hydroxybutyl acrylate (4-HBA) (manufactured by Osaka Organic Chemical Industry Ltd.), 125 parts of an organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

Example 16

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 60 parts of the “SHIKOH UV-7600B” manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., 40 parts of 4-hydroxybutyl acrylate (4-HBA) (manufactured by Osaka Organic Chemical Industry Ltd.), 125 parts of an organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

Example 17

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 80 parts of the “SHIKOH UV-7600B” manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., 20 parts of N-(2-hydroxyethyl) acrylamide (HEAA) (manufactured by KOHJIN Holdings Co., Ltd.), 125 parts of an organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

Example 18

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 70 parts of the “SHIKOH UV-7600B” manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., 30 parts of 4-hydroxybutyl acrylate (4-HBA) (manufactured by Osaka Organic Chemical Industry Ltd.), 10 parts of a dispersion liquid containing 30% of alumina having a surface covered with an organic compound (manufactured by BYK-Chemie Japan, NANOBYK-3610, solid content: 37 wt %, solvent: propylene glycol monomethyl ether acetate), 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 100), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

Example 19

An optical laminate was obtained in the same manner as in Example 1 except that: a composition for forming a hard coat layer was used, which was prepared by mixing 70 parts of the “SHIKOH UV-7600B” manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., 30 parts of 4-hydroxybutyl acrylate (4-HBA) (manufactured by Osaka Organic Chemical Industry Ltd.), 10 parts of the zirconia dispersion liquid obtained in Production Example 2, 5 parts of a leveling agent (manufactured by DIC Corporation, trade name: GRANDIC PC-4100, solid content: 10%), and 3 parts of a photopolymerization initiator (manufactured by Ciba Specialty Chemicals, trade name: IRGACURE 907), and diluting the mixture with methyl isobutyl ketone so that a solid content concentration became 50%; and the heating temperature of the application layer was set to 90° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 2 below shows the results.

TABLE 2 Adhesiveness Thickness Composition for forming hard coat layer Heating Scratch (number of Content Monofunctional temperature resistance Pencil of peeled Interference penetration Curable compound Inorganic nanoparticles (wt %) monomer (° C.) 400 g 600 g hardness crosscuts) unevenness layer (μm) Example UNIDIC 17-806 Opstar Z7540 24.7 4-HBA 90 4 4 3H 0 4 2.5 12 Isocyanuric acid Dipentaerythritol Silica triacrylate/pentaerythritol hexaacrylate/isophorone triacrylate/dipentaerythritol diisocyanate-based hexaacrylate/isophorone polyurethane diisocyanate-based acrylate polyurethane acrylate Example A-DPH Opstar Z7540 24.7 4-HBA 90 4 4 3H 0 4 4.2 13 Dipentaerythritol Dipentaerythritol Silica hexaacrylate hexaacrylate/isophorone diisocyanate-based polyurethane acrylate Example UV-7600B Opstar Z7540 2 4-HBA 90 4 3 2H 0 4 2.7 14 Hexafunctional urethane Dipentaerythritol Silica acrylic hexaacrylate/isophorone oligomer/pentaerythritol diisocyanate-based tetraacrylate/pentaerythritol polyurethane triacrylate acrylate Example UV-7600B Opstar Z7540 24.7 4-HBA 90 4 4 3H 0 4 2.7 15 Hexafunctional urethane Dipentaerythritol Silica acrylic hexaacrylate/isophorone oligomer/pentaerythritol diisocyanate-based tetraacrylate/pentaerythritol polyurethane triacrylate acrylate Example UV-7600B Opstar Z7540 24.7 4-HBA 90 4 4 3H 0 4 3.5 16 Hexafunctional urethane Dipentaerythritol Silica acrylic hexaacrylate/isophorone oligomer/pentaerythritol diisocyanate-based tetraacrylate/pentaerythritol polyurethane triacrylate acrylate Example UV-7600B Opstar Z7540 24.7 HEAA 90 4 4 3H 0 4 2.5 17 Hexafunctional urethane Dipentaerythritol Silica acrylic hexaacrylate/isophorone oligomer/pentaerythritol diisocyanate-based tetraacrylate/pentaerythritol polyurethane triacrylate acrylate Example UV-7600B NANOBYK-3610 2.9 4-HBA 90 3 3 2H 0 4 2.7 18 Hexafunctional urethane Alumina acrylic oligomer/pentaerythritol tetraacrylate/pentaerythritol triacrylate Example UV 7600B Production 3.2 4-HBA 90 3 3 2H 0 4 2.7 19 Example 2 Hexafunctional urethane Zirconia acrylic oligomer/pentaerythritol tetraacrylate/pentaerythritol triacrylate

Comparative Example 1

An optical laminate was obtained in the same manner as in Example 1 except that: pentaerythritol triacrylate (manufactured by Osaka Organic Chemical Industry Ltd., trade name: VISCOAT #300) was used instead of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540) was not added. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

Comparative Example 2

An optical laminate was obtained in the same manner as in Example 1 except that: dipentaerythritol hexaacrylate (manufactured by Shin Nakamura Chemical Co., Ltd., trade name: A-DPH) was used instead of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540) was not added. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

Comparative Example 3

An optical laminate was obtained in the same manner as in Example 1 except that: a mixture of 60 parts of a hexafunctional urethane acrylic oligomer, 30 parts of pentaerythritol tetraacrylate, and 10 parts of pentaerythritol triacrylate (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540) was not added. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

Comparative Example 4

An optical laminate was obtained in the same manner as in Example 1 except that the organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540) was not added. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

Comparative Example 5

An optical laminate was obtained in the same manner as in Example 1 except that: dipentaerythritol hexaacrylate (manufactured by Shin Nakamura Chemical Co., Ltd., trade name: A-DPH) was used instead of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 2,000 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

Comparative Example 6

An optical laminate was obtained in the same manner as in Example 1 except that: hexafunctional urethane acrylic oligomer (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the content of the organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540) was changed from 5 parts to 2,000 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

Comparative Example 7

An optical laminate was obtained in the same manner as in Example 1 except that: the UV-curable resin(manufactured by DIC Corporation, trade name: UNIDIC 17-806) was not used; and the content of the organic-inorganic hybrid resin containing inorganic nanoparticles (manufactured by JSR Corporation, trade name: Opstar Z7540, solid content: 56%, solvents: butyl acetate/methyl ethyl ketone) was changed from 5 parts to 100 parts. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

Comparative Example 8

An optical laminate was obtained in the same manner as in Example 1 except that: a mixture of 60 parts of a hexafunctional urethane acrylic oligomer, 30 parts of pentaerythritol tetraacrylate, and 10 parts of pentaerythritol triacrylate (manufactured by The Nippon Synthetic Chemical Industry Co., Ltd., trade name: SHIKOH UV-7600B) was used instead of 100 parts of the UV-curable resin (manufactured by DIC Corporation, trade name: UNIDIC 17-806); and the heating temperature of the application layer was set to 80° C. The optical laminate was subjected to the evaluations in the sections (1) to (5). Table 3 below shows the results.

TABLE 3 Thick- Adhesive- ness ness Inter- of pene- Composition for forming hard coat layer Scratch (number of ference tration Inorganic Content resistance Pencil peeled uneven- layer Curable compound nanoparticles (wt %) 400 g 600 g hardness crosscuts) ness (μm) Comparative VISCOAT #300 — — 1 1 H 0 4 7.5 Example 1 Pentaerythritol triacrylate Comparative A-DPH — — 2 2 H 0 4 2.5 Example 2 Dipentaerythritol hexaacrylate Comparative UV-7600B — — 1 1 2H 0 4 1.5 Example 3 Hexafunctional urethane acrylic oligomer/pentaerythritol tetraacrylate/pentaerythritol triacrylate Comparative UNIDIC 17-806 — — 1 1 3H 0 4 1.7 Example 4 Isocyanuric acid triacrylate/pentaerythritol triacrylate/dipentaerythritol hexaacrylate/isophorone diisocyanate-based polyurethane acrylate Comparative A-DPH Opstar Z7540 55.1 1 1 3H 0 1 2.0 Example 5 Dipentaerythritol hexaacrylate Dipentaerythritol Silica hexaacrylate/ isophorone diisocyanate- based polyurethane acrylate Comparative UV-7600B Opstar Z7540 55.1 1 1 3H 0 1 1.7 Example 6 Hexafunctional urethane acrylic Dipentaerythritol Silica oligomer/pentaerythritol hexaacrylate/ tetraacrylate/pentaerythritol isophorone triacrylate diisocyanate- based polyurethane acrylate Comparative Opstar Z7540 60 1 1 2H 0 1 1.5 Example 7 Dipentaerythritol hexaacrylate/isophorone Silica diisocyanate-based polyurethane acrylate Comparative UV-7600B — — 4 3 3H 100 1 0.5 Example 8 Hexafunctional urethane acrylic oligomer/pentaerythritol tetraacrylate/pentaerythritol triacrylate

As is apparent from Tables 1 and 2, the optical laminate of the present invention is excellent in adhesiveness between the base material film ((meth)acrylic resin film) and the hard coat layer because the optical laminate has the penetration layer having a predetermined thickness. The optical laminate of the present invention has the hard coat layer formed of the composition for forming a hard coat layer containing a specific amount of inorganic nanoparticles, and hence the optical laminate is excellent in scratch resistance as well while having excellent adhesiveness as described above. In addition, when the content of the inorganic nanoparticles in the composition for forming a hard coat layer is additionally adjusted and a penetration layer having a predetermined thickness is formed, an optical laminate that not only is excellent in adhesiveness and scratch resistance as described above but also shows small interference unevenness can be obtained (Examples 1 to 7 and 9 to 19).

INDUSTRIAL APPLICABILITY

The optical laminate of the present invention can be suitably used in an image display apparatus. The optical laminate of the present invention can be suitably used as the front plate of an image display apparatus or a protective material for a polarizer and can be particularly suitably used as the front plate of a liquid crystal display apparatus (especially a three-dimensional liquid crystal display apparatus).

REFERENCE SIGNS LIST

-   -   1 inorganic nanoparticle     -   10 base material layer     -   20 penetration layer     -   30 hard coat layer     -   100, 200 optical laminate 

The invention claimed is:
 1. An optical laminate for an image display apparatus, comprising: a base material layer formed of a (meth)acrylic resin film; a hard coat layer formed by applying, to the (meth)acrylic resin film, a composition for forming a hard coat layer containing a curable compound and inorganic nanoparticles; and a penetration layer having a thickness of 1.2 μm or more and wherein an upper limit for the thickness of the penetration layer is (thickness of the (meth)acrylic resin film×70% μm), the penetration layer being formed between the base material layer and the hard coat layer by penetration of the composition for forming a hard coat layer into the (meth)acrylic resin film, wherein a content of the inorganic nanoparticles is 1.5 wt % to 30 wt % with respect to a total of the curable compound and the inorganic nanoparticles, and wherein the composition for forming a hard coat layer contains a curable compound having 2 to 4 (meth)acryloyl groups, and a content of the curable compound having 2 to 4 (meth)acryloyl groups is 85 wt % or less with respect to all curable compounds in the composition for forming a hard coat layer wherein the composition for forming a hard coat layer further contains a curable compound having 5 or more (meth)acryloyl groups, and a content of the curable compound having 5 or more (meth)acryloyl groups is 15 wt % to 70 wt % with respect to all curable compounds in the composition for forming a hard coat layer, and wherein the composition for forming a hard coat layer further contains a monofunctional monomer, and a content of the monofunctional monomer is 40 wt % or less with respect to all curable compounds in the composition for forming a hard coat layer.
 2. An optical laminate for an image display apparatus according to claim 1, wherein at least part of a surface of each of the inorganic nanoparticles is covered with an organic compound.
 3. An optical laminate for an image display apparatus according to claim 2, wherein the organic compound comprises an organic compound having a polymerizable unsaturated group.
 4. An optical laminate for an image display apparatus according to claim 1, wherein the monofunctional monomer has a weight-average molecular weight of 500 or less.
 5. An optical laminate for an image display apparatus according to claim 1, wherein the monofunctional monomer has a hydroxyl group.
 6. An optical laminate for an image display apparatus according to claim 5, wherein the monofunctional monomer comprises a hydroxyalkyl (meth)acrylate and/or an N-(2-hydroxyalkyl) (meth)acrylamide.
 7. An optical laminate for an image display apparatus according to claim 1, wherein the (meth)acrylic resin film has a transmittance for light having a wavelength of 380 nm of 15% or less.
 8. An optical laminate for an image display apparatus according to claim 1, wherein a (meth)acrylic resin forming the (meth)acrylic resin film has a structural unit expressing positive birefringence and a structural unit expressing negative birefringence.
 9. An optical laminate for an image display apparatus according to claim 1, wherein a (meth)acrylic resin forming the (meth)acrylic resin film has a weight-average molecular weight of 10,000 to 500,000.
 10. An optical laminate for an image display apparatus according to claim 1, wherein in the hard coat layer and the penetration layer, a concentration of a (meth)acrylic resin forming the (meth)acrylic resin film continuously reduces from a side of the penetration layer close to the base material layer to a side of the hard coat layer opposite to the base material layer.
 11. An optical laminate for an image display apparatus according to claim 1, wherein a surface of the hard coat layer opposite to the penetration layer has an uneven structure.
 12. An optical laminate for an image display apparatus according to claim 1, further comprising an antireflection layer on a side of the hard coat layer opposite to the penetration layer.
 13. A polarizing film, comprising the optical laminate for an image display apparatus according to claim
 1. 14. An image display apparatus, comprising the optical laminate for an image display apparatus according to claim
 1. 